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At least 379 records · Page 21

High-Temperature, High-Flux Multifoil Shield Developed for Space Applications

Spacecraft employing solar dynamic power systems typically use parabolic, point focus concentrators to collect solar power and direct it to the aperture of a heat receiver. Solar fluxes several thousand times the intensity of one solar constant are typically produced in the focal plane of such concentrators. Under heat loading this severe, passively cooled surfaces constructed of most engineering materials would rapidly melt. Therefore, high-temperature shielding is required to protect heat receiver surfaces and other spacecraft surfaces that may be exposed to high flux. To meet this challenge for the joint U.S./Russian Solar Dynamic Flight Demonstration Program, AlliedSignal Aerospace and the NASA Lewis Research Center developed a high-temperature, high-flux multifoil shield tolerant of extreme heat loading conditions in a vacuum environment. The shield is passively cooled, obviating the need for pumped fluid loops and/or heat pipe cooling systems with their attendant cost, mass, complexity, and reliability issues.

Kerslake, Thomas W.↗

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems↗

Earth Source Heat: A Cascaded Systems Approach to DDU of Geothermal Energy on the Cornell Campus

This report documents the completion of the DOE study DE-EE0008103: Earth Source Heat: A Cascaded Systems Approach to DDU of Geothermal Energy on the Cornell Campus. This study involved a comprehensive evaluation of the potential for Earth Source Heat (ESH), Cornell’s specific application of Deep Direct Use (DDU) geothermal energy, to create a viable renewable source of thermal energy for its Ithaca, NY campus district heating system. The study included stochastic modeling that married each of two potential subsurface resources (two specific geological reservoirs) to documented campus heating operations based on hourly campus heating profiles and proposed integrated equipment controls (variable speed pumps and heat pumps). The outputs of the subsurface modeling were used as inputs for a Cornell-developed surface heat use Excel-based modeling program (the program was named “Modeled ENergy Use”, or “MEnU”). This allowed Cornell to compute realistic annual totals of extractable and useable heat for the campus, including details like heat losses, minimum summer demand, and controllable building temperature settings. The Cornell team then evaluated the costs and benefits of each modeled scenario. The primary evaluation was a standard “single bottom line” economic calculation for the Levelized Cost of Heat (LCOH). This represents the annualized cost (per unit heat) for Cornell. Additional valuations were also computed based on the benefit to the environment and to the regional economy (i.e., economic benefits external to campus). The results of this study demonstrate that if suitable reservoir flow can be attained, Earth Source Heat would be a viable technology to supply Cornell’s district heating system. This viability is based on the following criteria: (1) The modeled system produced a total useable heat output that exceeded the minimum annual campus heat load determined at the onset of the project (i.e., offsetting at least 20% of the annual campus thermal load). The output range is substantial depending on both the subsurface resource and the surface applications; at the high end, our modeled solutions produced up to ~70% of existing campus heat load with a single well pair producing 70 kg/s with integrated high-temperature heat pumps, and (2) Modeling demonstrated that multiple geothermal reservoirs could provide economically viable results when heat pumps were strategically integrated, a design that has been proven in at least one European installation already. In this context, “economically viable” means that the LCOH for the project is less than the regional commercial price of heat that would be generated using natural gas (the most common and cheapest fossil alternative in our area). Based on a single-bottom-line (LCOH) valuation, our results show that economic success is likely for any reservoir deeper than about 2.25 km where a sufficient permeability exists (or can be created with stimulation or similar engineering enhancement) and reasonable production temperatures sustained over time. The LCOH values of $\$ 4.77$ to $\$ 6.46$ per MMBtu are all lower than the comparable cost of providing heat energy with a natural gas boiler for a facility in the Northeast U.S. that obtains natural gas at commercial rates (Commercial heat costs would include at least $\$ 9.41$ in fuel costs, representing total boiler/transfer efficiency of 85% using gas at $\$ 8.00$ per MMBtu; LCOH would be higher if capital equipment and other operating costs were included). In addition to LCOH, Cornell’s scope also included evaluation of the Environmental value and Regional Economic value of each scenario. When considering the environmental and regional economic value of such a project, the overall “triple bottom line” cost (i.e., the LCOH less the LCOH ENV and LCOH REG values) is even lower and in some cases negative; i.e., in some cases a project achieving the listed performance would have higher value to the environment and to the regional economy than the total project costs over the 30-year project timeframe.

15 GEOTHERMAL ENERGY↗

Tritium retention in reduced-activation ferritic/martensitic steels

Reduced-activation ferritic/martensitic (RAFM) steels are structural material candidates for breeding blankets of future fusion reactors. Therefore, tritium (T) retention in RAFM steels is an important problem in assessing the T inventory of blankets. In this study, specimens of RAFM steels were subjected to irradiation of 20 MeV W ions to 0.54 displacements per atom (dpa), exposure to high flux D plasmas at 400 and 600 K and that to pulsed heat loads. The specimens thus prepared were exposed to DT gas at 473 K. Despite severe modification in the surface morphology, heat loads had negligible effects on T retention. Significant increase in T retention at the surface and/or subsurface was observed after D plasma exposure. However, T trapped at the surface/subsurface layer was easily removed by maintaining the specimens in the air at about 300 K. Displacement damage led to increase in T retention in the bulk due to the trapping effects of defects, and T trapped was stable at 300 K. It was therefore concluded that displacement damages had the largest influence on T retention under the present conditions.

36 MATERIALS SCIENCE↗

Assembly and commissioning of a new SRF cryomodule for the ATLAS intensity upgrade

The Argonne National Laboratory Physics Division is in the final stages of a major upgrade to the Argonne Tandem Linear Accelerator System national user facility, referred to as the intensity upgrade. The intensity upgrade project will substantially increase beam currents for experimenters working with the existing ATLAS stable and in-flight rare isotope beams and for the neutron-rich beams from the Californium Rare Isotope Breeder Upgrade. This project includes the replacement of three existing cryomodules, containing 18 superconducting accelerator cavities and 9 superconducting solenoids, with a single cryomodule with seven SC 72.75 MHz accelerator cavities optimized for ion velocities of 7.7% the speed of light and 4 SC solenoids all operating at 4.5 K. This presentation will report: how we minimized the heat load into the 4 K and 80 K coolant streams feeding the cryomodule, a comparison of the calculated and measured static heat loads at 80 K and the mechanical design of the vacuum vessel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of a Thermo-Electric Cooler Simulation Routine for the Wide Field Camera 3 Thermal Model

A SINDA subroutine has been developed to predict the power generated by a Thermo-Electric Cooler (TEC). A TEC can be described analytically by relations between four parameters: cold side temperature, hot side temperature, parasitic heat load, and electrical power. The subroutine requires the user to input the hot side and cold side temperatures, the corresponding parasitic heat load, and coefficients describing the vendor performance curves. The subroutine then utilizes an iterative solution scheme and vendor TEC performance curves for specific hardware to determine the current (and consequently the TEC power) that satisfies these requirements. This paper provides an in-depth discussion of the algorithm employed in the subroutine, implementation of the subroutine in the HST Wide Field Camera 3 thermal model, and the evaluation of the subroutine performance against actual test/correlation data.

Peabody, Hume↗

Concept Design a 1.4 MW Inverter for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Concept design↗

Concept Design of a 1.4 MW Drive for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near-term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5% efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Cryogenic↗

Thermal Design of Vapor Cooling of Flight Vehicle Structures Using LH2 Boil-Off

Using hydrogen boil-off vapor to cool the structure of a flight vehicle cryogenic upper stage can reduce heat loads to the stage and increase the usable propellant in the stage or extend the life of the stage. The hydrogen vapor can be used to absorb incoming heat as it increases in temperature before being vented overboard. In theory, the amount of heat leaking into the hydrogen tank from the structure will be reduced if the structure is cooled using the propellant boil-off vapor. However, the amount of boil-off vapor available to be used for cooling and the reduction in heat leak to the propellant tank are dependent to each other. The amount of heat leak reduction to the LH2 tank also depends on the total heat load on the stage and the vapor cooling configurations.

heat transfer↗

Integrated thermal-structural analysis of large space structures

Optimum performance of large space antennas requires very fine control of the shape of the antenna surface since the shape affects both frequency control and pointing accuracy. A significant factor affecting the antenna shape is the temperature of the structure and the resulting deformation. To accurately predict the temperature of the structure, it is necessary first to accurately predict thermal loads. As the structure orbits the Earth, the thermal loads change constantly so that the thermal-structural response varies continuously throughout the orbit. The results from recent applications of integrated finite element methodology to heat load determination and thermal-structural analysis of large space structures are given. Four areas are concentrated on: (1) the characteristics of the integrated finite element methodology, (2) fundamentals of orbital heat load calculation, (3) description and comparison of some radiation finite elements, and (4) application of the integrated finite-element approach to the thermal-structural analysis of an orbiting truss structure.

Mahaney, J.↗

Measure Guideline: Condensing Boilers - Optimizing Efficiency and Response Time During Setback Operation

Conventional wisdom surrounding space heating has told us a couple of things consistently for several years now: size the mechanical systems to the heating loads and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. Determining the appropriateness of setback for a particular project is the first step. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step by step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Hydronic Systems: Designing for Setback Operation, Ithaca, New York [Fact Sheet]

Conventional wisdom surrounding space heating has told us a couple of things consistently for several years now: size the mechanical systems to the heating loads and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. Determining the appropriateness of setback for a particular project is the first step. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step by step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Measure Guideline: Condensing Boilers-Optimizing Efficiency and Response Time During Setback Operation

Conventional wisdom surrounding space heating has consistently stated two things: size the mechanical systems to the heating loads, and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. The first step is to determine the appropriateness of setback for a particular project. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step-by-step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Fatigue-test acceleration with flight-by-flight loading and heating to simulate supersonic-transport operation

Possibilities for reducing fatigue-test time for supersonic-transport materials and structures were studied in tests with simulated flight-by-flight loading. In order to determine whether short-time tests were feasible, the results of accelerated tests (2 sec per flight) were compared with the results of real-time tests (96 min per flight). The effects of design mean stress, the stress range for ground-air-ground cycles, simulated thermal stress, the number of stress cycles in each flight, and salt corrosion were studied. The flight-by-flight stress sequences were applied to notched sheet specimens of Ti-8Al-1Mo-1V and Ti-6Al-4V titanium alloys. A linear cumulative-damage analysis accounted for large changes in stress range of the simulated flights but did not account for the differences between real-time and accelerated tests. The fatigue lives from accelerated tests were generally within a factor of two of the lives from real-time tests; thus, within the scope of the investigation, accelerated testing seems feasible.

Imig, L. A.↗

Arc Jet Testing of the TIRS Cover Thermal Protection System for Mars Exploration Rover

This paper summarizes the arc jet test results of the Mars Exploration Rover (MER) Silicone Impregnated Reusable Ceramic Ablator (SIRCA) Transverse Impulse Rocket System (TIRS) Cover test series in the Panel Test Facility (PTF) at NASA Ames Research Center (ARC). NASA ARC performed aerothermal environment analyses, TPS sizing and thermal response analyses, and arc jet testing to evaluate the MER SIRCA TIRS Cover design and interface to the aeroshell structure. The primary objective of this arc jet test series was to evaluate specific design details of the SIRCA TIRS Cover interface to the MER aeroshell under simulated atmospheric entry heating conditions. Four test articles were tested in an arc jet environment with various sea] configurations. The test condition was designed to match the predicted peak flight heat load at the gap region between the SIRCA and the backshell TPS material, SLA-561S, and resulted in an over-test (with respect to heat flux and heat load) for the apex region of the SIRCA TIRS Cover. The resulting pressure differential was as much as twenty times that predicted for the flight case, depending on the location, and there was no post-test visual evidence of over-heating or damage to the seal, bracket, or backshell structure. The exposed titanium bolts were in good condition at post-test and showed only a small amount of oxidation at the leading edge locations. Repeatable thermocouple data were obtained and SIRCA thermal response analyses were compared to applicable thermocouple data. For the apex region of the SIRCA TIRS Cover, a one-dimensional thermal response prediction proved overly conservative, as there were strong multi-dimensional conduction effects evident from the thermocouple data. The one-dimensional thermal response prediction compared well with the thermocouple data for the leading edge "lip" region at the bolt location. In general, the test results yield confidence in the baseline seal design to prevent hot gas ingestion at the bracket and composite aeroshell structure interface.

Szalai, Christine E.↗

Design and performance evaluation of a cryogenic condenser for an in-pile experiment

An apparatus was designed to enable in-pile irradiation of materials in liquid hydrogen at cryogenic temperatures. One of the principal components of this apparatus was a horizontal tube condenser. The performance of the condenser was evaluated by running a liquid-nitrogen prototype of the apparatus at heat loads comparable to or greater than those expected during the irradiation. The test showed that the condenser was capable of handling the design heat load and that the design procedure was sound.

Graham, R. W.↗

Waste Classification based on Waste Form Heat Generation in Advanced Nuclear Fuel Cycles Using the Fuel-Cycle Integration and Tradeoffs (FIT) Model

This study explores the impact of wastes generated from potential future fuel cycles and the issues presented by classifying these under current classification criteria, and discusses the possibility of a comprehensive and consistent characteristics-based classification framework based on new waste streams created from advanced fuel cycles. A static mass flow model, Fuel-Cycle Integration and Tradeoffs (FIT), was used to calculate the composition of waste streams resulting from different nuclear fuel cycle choices. This analysis focuses on the impact of waste form heat load on waste classification practices, although classifying by metrics of radiotoxicity, mass, and volume is also possible. The value of separation of heat-generating fission products and actinides in different fuel cycles is discussed. It was shown that the benefits of reducing the short-term fission-product heat load of waste destined for geologic disposal are neglected under the current source-based radioactive waste classification system , and that it is useful to classify waste streams based on how favorable the impact of interim storage is in increasing repository capacity.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Erosion products of plasma facing materials formed under ITER-like transient load and deuterium retention in them

Erosion of the plasma-facing materials in particular evaporation of the materials in a fusion reactor under intense transient events is one of the problems of the ITER. The current experimental data are insufficient to predict the properties of the erosion products, a significant part of which will be formed during transient events (edge-localized modes (ELMs) and disruptions). The paper concerns the experimental investigation of the graphite and tungsten erosion products deposited under pulsed plasma load at the QSPA-T: heat load on the target was 2.6 MJ/m{sup 2} with 0.5 ms pulse duration. The designed diagnostics for measuring the deposition rate made it possible to determine that the deposition of eroded material occurs during discharge, and the deposition rate is in the range (0.1–100) × 10{sup 19} at/(cm{sup 2} s), which is much higher than that for stationary processes. It is found that the relative atomic concentrations D/C and D/(W + C) in the erosion products deposited during the pulse process are on the same level as for the stationary processes. An exposure of erosion products to photonic energy densities typical of those expected at mitigated disruptions in the ITER (pulse duration of 0.5–1 ms, integral energy density of radiation of 0.1–0.5 MJ/m2) significantly decreases the concentration of trapped deuterium.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗